Water softener for use with an automatic washing machine



June 4, 1968 B. J. BREZOSKY WATER SOFTENER FOR USE WITH AN AUTOMATICWASHING MACHINE Filed March 50, 1966 2 Sheets-Sheet 1 FlG.l

v-us TToRUEV 4 5 3%. l A j 1 A h l 2 4'4- fl 33 June 4, 1968 B. J.BREZOSKY 3,386,582

WATER SOFTENER FOR USE WITH AN AUTOMATIC WASHING MACHINE Filed March 50,1966 2 Sheets-Sheet 2 FIG].

INVENTOR. BERNARD I BREZOSKY BY F g {1 ms ATTQRMEQ United States Patent3,386,582 WATER SOFTENER FOR USE WITH AN AUTOMATIC WASHING MACHINEBernard J. Brezosky, Louisville, Ky., assignor to General ElectricCompany, a corporation of New York Filed Mar. 30, 1966, Ser. No. 533,7067 Claims. (Cl. 210-436) ABSTRACT OF THE DISCLOSURE An improved watersoftener for an automatic washing machine, The softener is of theregenerative ion-exchange resin type including a resin containingchamber and an adjacent liquid inlet chamber. The inlet chamber is madesubstantially rectangular and either or both of its respective inletspouts for raw Water and for regenerating solution are angularlyoriented relative to the inlet chamber wall to provide uniformdistribution of these liquids throughout the cross-sectional area of theadjacent resin chamber. The regenerating solution spout is restricted togive jet action and also includes a check valve to prevent back flowfrom the softener to the source of regenerating solution.

This invention relates generally to an improved water softener and, morespecifically, to a watersoftener particularly adapted for use with anautomatic washing machine.

When a water softener is adapted for integral use with an automaticwashing machine such as, for example, an automatic dishwasher, thedesign requirements involve space limitations. This is particularly truewhen it is desired to incorporate a water softener into an automaticwashing machine without increasing the overall dimensions of the washingmachine. Moreover, in the present era of sophisticated homemakers, anyimprovement in automatic washing machines must not compromise theautomatic feature of the machine. Therefore, a water softener integratedwith an automatic washing machine must be automatically operative andautomatically regenerated if it is to be commercially acceptable. Theforegoing factors place strict design limitation on any water softenerproposed for incorporation into an automatic washing machine. Becausethe size is limited, the efficiency of the water softener must bemaximized so that the limited amount of ion-exchange media willadequately reduce the calcium content of the volume of water necessarywithin the time available. Since this operation must be automatic, andintegrated with the normal operational cycle of the washing machine,regeneration of the ion-exchange media must take place automatically andmust not unreasonably elongate the overall operational cycle of theautomatic washing machine. Therefore, regeneration must take placewithin the shortest time possible.

In view of these criteria, flow through the ion-exchange media duringboth the softening process and the regeneration process becomescritical. If the flow of water through the ion-exchange media issubstantially evenly distributed throughout the cross-sectional area ofthe chamber containing the media, the media is more efficiently utilized during softening process and therefore the amount of media can bekept to a minimum. Similarly, if the flow of regenerating solution intothe chamber containing the ion-exchange media is substantially uniformlydistributed throughout the cross-sectional area of the chamber,regeneration is more eflicient, resulting in less solution and shortertime being required for regeneration.

Accordingly, it would be desirable to provide in a water softener foruse with an automatic washing machine 3,386,582 Patented June 4, 1968means to cause substantially even distribution, throughout thecross-sectional area of the chamber containing the ion-exchange media,of both water flowing through the media during softening andregenerating solution flowing into the chamber during regeneration.

It is an object of the present invention to provide an improved watersoftener particularly adapted for use with an automatic washing machine.

It is another object of this invention to provide means in a watersoftener to assure reasonably even distribution of flow throughout thecross-sectional area of the chamber containing the ion-exchange mediaduring the softening process.

It is another object of this invention to provide means in a watersoftener to assure reasonably even distribution of flow into thecross-sectional area of the chamber containing the ion-exchange mediaduring regeneration of the ion-exchange media.

Briefly stated, in accordance with one aspect of the present invention,there is provided a water softener, for use with an automatic washingmachine, comprising a resin chamber adapted to receive and contain anion-exchange mcdia. A substantially rectangular inlet chamber isprovided adjacent to, and in liquid communication with, the resinchamber. A spout is provided in one wall of the inlet chamber to admitwater to the inlet chamber and the spout has an angled relationship withthat wall to direct the incoming water in a substantially diagonaldirection across the inlet chamber.

In accordance with another aspect of the invention, a spout to admitregenerating solution to the inlet chamber is provided and has a reducedinternal diameter to provide increased velocity of the regeneratingsolution as it leaves the spout and enters the inlet chamber. This spoutmay also be angled with respect to the wall of the chamber to direct theincoming regenerating solution in a substantially diagonal directionacross the inlet chamber.

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as theinvention, it is believed the invention will be better understood fromthe following description taken in connection with the accompanyingdrawings, in which:

FIGURE 1 is a side view, partly cut away to show details, of anautomatic dishwasher employing the present invention;

FIGURE 2 is an elevational view, partly cut away to show details, of thewater softener of the present invention;

FIGURE 3 is a sectional view taken along line 3-3 of FIGURE 2; and

FIGURE 4 is a fragmentary sectional view taken along line 4-4 of FIGURE3.

Referring now to the drawings, and particularly to FIGURE 1 thereof, anautomatic dishwasher 10 is provided with an outer cabinet 11 definingtherein a wash chamber 12. Access to wash chamber 12 is provided bymeans of a closure member or door 13 which pivots about a substantiallyhorizontal axis defined by a pair of hinges 14, only one of which isvisible in FIGURE 1. Dish-sup porting racks 15 and 16 are providedwithin wash chamber 12 to support dishes or other articles to be washedtherein.

The bottom wall 17 of wash chamber 12 has a centrally depressed portionforming a sump 18 wherein wash fluid or other liquids will collect.Disposed within sump 18, and supported by bottom wall 17, is amotor-pump assembly 19 including an electrically-reversible motor 20 anda pump 21. Pump 21 is provided with an inlet 22 through which fluid iswithdrawn by pump 21 from sump 18 and, in one direction of rotation ofmotor 20, is propelled through an effluent discharge outlet 23 and, inthe opposite direction of rotation of motor 20, is propelled upwardlyinto a spray means or spray arm 24. Spray arm 24 is mounted on the topof pump 21 for rotation about a substantially vertical axis and isprovided with a plurality of orifices which eject the fluid pumped bypump 21 upwardly into wash chamber 12 to effectuate a wash action uponarticles supported by racks 15 and 16. Certain of the orifices in arm 24are directed in a manner whereby the reaction force created by theejection of the fluid causes arm 24 to rotate,

A generally annular electrical-resistance heating ele ment 25 issupported by bottom wall 17 at one point by means of a bracket 26 and atanother point by means of a flange 27 on element 25 and a threaded nut28. Heating element 25 has an electrical terminal 29 to which anelectrical conductor (not shown) may be connected to provide electricalenergy to heating element 25. Heating element 25 may be employed to heatwash fluid present within the wash chamber 12 during the washing and/orrinsing operation of the dishwasher however, the more important functionof heating element 25 is to effectuate drying of articles supported byracks and 15 upon completion of the washing and rinsing operations.

With the foregoing arrangement, a conventional complete dishwasher cycleof operation includes initially the admission of water into the washchamber 12.. After a sufficient quantity of water has been admitted towash chamber 12, motor is energized to rotate in a direction wherein thewater is pumped by pump 21 up through spray arm 24 to effectuate apre-rinse of the articles supported by racks 15 and 16. Motor 20 is thende-energized and then re-energized in the opposite direction of rotationso that Water is withdrawn from sump 13 and pumped out through dischargeoutlet 23. This sequence of events is repeated several times with atleast one of the times including the addition of a detergent to thewater. Following the final rinse, heating element is energized to heatthe air within wash chamber 12 to facilitate drying of articlessupported by racks 15 and 16. After completion of this drying cycle, allcomponents of the dishwasher are de-energized and the complete cycle ofoperaation is terminated.

A water softener 30 is supported on the inner surface of outer cabinet11, below bottom wall 17, :by means of a bracket 31. Referring brieflyto FIGURE 2, it can be seen that water softener 34 is shapedsubstantially like a rectangular box and includes a resin chamber 32.Resin chamber 32 is defined at its upper extremity by an upperperforated partition or screen 33 and at its lower extremity by a lowerperforated partition or screen 34-. Screens 33 and 34 have openingstherethrough which allow water or other liquid to pass through but whichprevent passage of the particulate ion-exchange resin, or otherion-exchange media, disposed within resin chamber 32. An opening 35 isprovided in one wall of resin chamber 32 so that the ion-exchange mediamay be replenished or replaced if necessary. Opening 35 is provided withthreads 36 which receive a threaded cap (not shown) to prevent theescape of liquid or ion-exchange media through opening 35. A rectangularinlet chamber 37 is defined at the lower portion of water softener 3G bylower screen 34 and the bottom wall of water softener 30. Similarly, anoutlet chamber 38 is defined at the upper portion of water softener 30by upper screen 33 and the upper wall of water softener 30. Outletchamber 33 has a port 39 which opens into a passageway 40 extendingdownwardly adjacent resin chamber 32. A port 41 provides communicationbetween the lower end of passageway 4t) and the lower portion of areservoir 42. Reservoir 42 has a series of bafiies 43 projectingthereinto from the side walls defining reservoir 42. An outlet 44 isprovided at the upper portion of reservoir 42.

With the foregoing arrangement, liquid entering inlet chamber 37 willpass upwardly through lower screen 34,

through resin chamber 32, through upper screen 33 and into outletchamber 38. From outlet chamber 38, the liquid will pass through port39, downwardly through passageway 40 and through port 41 into reservoir42. The liquid will then flow upwardly through reservoir 42, following atortuous path defined by baffles 43, and out through outlet 44.

Referring again to FIGURE 1, a water inlet conduit 45 is adapted forconnection to a source of hard water (not shown). In the case of aportable dishwasher such as that illustrated in FIGURE 1, conduit 45would be provided with means to removably connect it to a faucetassociated with a kitchen sink. Customarily, the conduit 45 would beconnected to the faucet at the beginning of the operational cycle of thedishwasher ltl and removed shortly after termination of the dishwashercycle. Such connection and disconnection frequently results in air beingtrapped within conduit 45 and, as will become obvious hereinafter, thisair can enter inlet chamber 37 creating an air lock therein. Waterentering dishwasher 1% through conduit 45 encounters twoelectricallyoperated valves 46 and 47. Valve 46 is operated by solenoid48 while valve 47 is operated by solenoid 49. When solenoid 48 opensvalve 46, water passes from conduit 45 through valve 46 into conduit 50.Water passing through conduit 50 enters inlet chamber 37 by means of aspout 51 (FIG- URE 3). Water thus entering inlet chamber 37 will passthrough water softener 30 in the manner described above and, as itpasses through outlet 44, it will enter conduit 52. Conduit 52 extendsacross dishwasher 10 below bot tom wall 17 and then upwardly outside ofwash chamber 12 in a compartment 53 defined by a housing 54 secured to,but having a wall spaced from, outer cabinet 11. Conduit 52 terminatesin an inverted U-shaped nozzle 55 which directs water into a fill funnel56 formed in the front wall of outer cabinet 11. Fill funnel 56 directsthe water issuing from nozzle 55 into wash chamber 12.

Thus, it can be seen that all water entering wash chamber 12 for thepurpose of washing or rinsing articles supported by racks 15 and 16passes through the resin chamber 32 of water softener 30. In order tointegrally associate the water softener with the dishwasher withoutincreasing the overall size of the dishwasher, it is necessary to limitthe size of the water softener. Accordingly, because the :size of thewater softener is limited, and in turn the size of the resin chamber 32is limited, it is necessary to periodically regenerate the ion-exchangemedia within resin chamber 32. To achieve regeneration, the valve 47 isopened by solenoid 49 and water is allowed to pass through valve 47 intoconduit 57. Conduit 57 extends up into compartment 53 and terminates ata regenerating agent container 58 which is provided with a funnel-likeinlet 59 so that regenerating agent may be inserted into container 58conveniently. Inlet 59 is provided with a removable cap 60 whichprevents water or wash fluid from entering container 58 during rinse orwash operation of the dishwasher 10. Water entering container 58 fromconduit 57 places the regenerating agent in solution and forces thesolution from container 58 into conduit 61. Conduit 61 extends downthrough compartment 53 and across dishwasher 10 below bottom wall 17 andcommunicates with inlet chamber 37 through a spout 62 (FIGURE 3). Thus,the regenerating solution entering inlet chamber 37 will, from thatpoint on, follow the course described above with respect to waterentering inlet chamber 37 through spout 51.

The most suitable regenerating agent for ion-exchange media is ordinarytable salt (sodium chloride). The water passing through container 58creates a saline solution which passes through conduit 61 and up throughthe ion-exchange media in chamber 32. As the saline solution is incontact with the ion-exchange granules, the granules release calciumions in exchange for sodium ions released by the saline solution in amanner well known in the water softening art. However, the regeneratingsolution maintains a relatively high degree of salinity afterregenerating the ion-exchange media. This high degree of salinity wouldprove corrosive to the components of the dishwater if it wereimmediately admitted to the dishwasher and allowed to remain therein forany substantial length of time.

Dishwasher is provided with a sequence control means (not shown) whichenergizes solenoid 49 to open valve 47 briefly at the one point duringthe operational cycle of dishwasher 10. This brief period during whichvalve 47 is opened results in the admission of saline solution in aquantity suflicient to immerse the ion-exchange media in chamber 32. Thesequence control means maintains valve 47 closed for several minutesduring which time regeneration of the ion-exchange media takes place.Following this, the sequence control means re-energizes solenoid 49 toopen valve 47 a second time. The second opening of valve 47 allows asecond charge of saline solution to enter resin chamber 32, displacingthe first charge into reservoir 42. The system remains in this conditionuntil solenoid 48 opens valve 46 to admit fresh water into resin chamber32 displacing the saline solution in reservoir 42 and in chamber 32.During this time, motor is energized to rotate pump 21 in a direction sothat any fluid entering pump 21 through inlet 22 will be dischargedthrough outlet 23. Thus, the saline solution is displaced throughconduit 52 into wash chamber 12 and immediately pumped into the sewersystem by pump 21. Ballies 43 in reservoir 42 provide a tortuous path toassure that the saline solution does not short circuit from port 41 tooutlet 44 during the time that the second charge of saline solution isbeing admitted to resin chamber 32. This minimizes the possibility ofsaline solution entering wash chamber 12 prior to the time when pump 21would with draw it therefrom and pump it out through outlet 23.

The foregoing arrangement is described and claimed in pendingapplication Ser. No. 538,707 of Norman L. Kendt, filed Mar. 30, 1966,for Dishwasher With Integral Water Softener, and assigned to the GeneralElectric Company, assignee of the present invention.

The present invention is directed toward means to cause substantiallyeven distribution, throughout the cross-sectional area of chamber 32, ofboth water flowing through the ion-exchange media within chamber 32during softening and regenerating solution flowing into chamber 32during regeneration. Because of height limitations, spouts 51 and 62 arelocated in side'by-side relationship rather than over and under. if thefresh water spout 51 were oriented squarely with the wall of inletchamber 37 through which it passes, the water would flow along theadjacent wall of inlet chamber 37 creating a swirling action around thewalls of inlet chamber 37 with extreme cavitation in the central area ofchamber 37. Two problems are created with such an arrangement, the firstproblem is that little or no water flows up through the central portionof the ion-exchange media within chamber 32, creating poor efliciencydue to the incomplete exposure of the media to the'water. Secondly,normal operation of a portable dishwasher, such as that illustrated inFIGURE 1, results in air being trapped in conduit 45, as describedabove. This air will form bubbles beneath lower screen 34 which, ineffect, provide an air lock which blocks flow up through the centralportion of the chamber 32. By orienting spout 51 in angular relationshipwith the wall of chamber 37, the incoming water is directedsubstantially diagonally across chamber 37 and into the opposite cornerwhere it is broken up by random agitation. This action breaks up the airbubbles and disperses the air lock by forcing the bubbles through screen34 and on through softener It also minimizes the swirling action whichwould otherwise be created.

The flow rate through spout 62, because it is handling regeneratingsolution, is significantly less than that through spout 51, and isapproximately .1 gallon per minute. This is because flow rate throughregenerating agent container 58 must be slow enough to allow theregenerating agent (sodium chloride) to dissolve in the solution withthe water entering container 58. Accordingly, flow out of container 58through conduit 61 is relatively low. With this low flow rate, if spout62 were oriented squarely with respect to the wall through which itpasses, the regenerating agent would only flow slowly along one side ofinlet chamber 37 and up along one side of chamber 32 thereby resultingin a very inefficient regeneration of the ion-exchange media withinchamber 32. Accordingly, spout 62 is oriented with respect to the wallthrough which it passes in a manner similar to the orientation of spout51 to provide more uniform distribution across the cross-sectional areaof chamber 37.

Moreover, the aforementioned low flow rate would result in theregenerating solution travelling only a short distance into chamber 37which again would result in inefficient regeneration of the ion-exchangemedia. To overcome this latter problem, the internal diameter of spout62 is tapered, as illustrated most clearly in FIGURE 4, or otherwiseconfigurated to increase the velocity of the regenerating solution as itleaves spout 62 and enters chamber 37. This increased velocity carriesit across chamber 37 for more even distribution throughout thecross-sectional area of chamber 37. Additionally, with the increasedvelocity, if spout 62 were squarely oriented with respect to the wallthrough which .it passes, it is pos sible that the aforementionedcavitation problem with respect to spout 51 would be created. Theangular relationship between spout 62 and the wall through which itpasses minimizes the likelihood of the cavitation problem duringregeneration.

Referring briefly to FIGURE 4, spout 62 is shown in detail and reveals acheck valve disposed therein. The check valve includes a movable member63 having an elongated stem 64 with a sealing member 65 in one endthereof. The purpose of the check valve is to prevent the flow of liquidfrom chamber 37 int o conduit 61. Such flow, if it were allowed tooccur, would result in fresh water finding its Way into container 5%.This fresh water would dissolve regenerating agent into solution and, asthe pressure within water softener 30 decreased, the saline regeneratingsolution would find its way into chamber 37 thereby contaminating thefresh water then contained within softener 30. FIGURE 4 illustrates thecheck valve in the closed position. In the open position, sealing member65' moves to the left until it engages surface 66. When in thisposition, liquid may flow around the outer periphery of the sealingmember 65 and through passages 67. Stem 64 simply maintains sealingmember 65 properly oriented with respect to the surface upon which itseats to prevent counterflow through spout 62.

Thus, it can be seen that the present invention provides, in a watersoftener for use in an automatic washing ma chine, means to causesubstantially even distribution, throughout the cross-sectional area ofthe chamber containing the ion-exchange media, of both water flowingthrough the media during softening and regenerating solution flowinginto the chamber during regeneration.

As will be evident from the foregoing descripton, certain aspects of theinvention are not limited to the particular details of construction ofthe example illustrated, and it is contemplated that various othermodifications or applications will occur to those skilled in the art. Itis therefore intended that the appended claims shall cover suchmodifications and applications as do not depart from the true spirit andscope of the invention.

What I claim as new and desire to secure by Letters Patent of the UnitedStates is:

1. A water softener for use in connection with an automatic washingmachine comprising:

(a) a resin chamber adapted to receive and contain an ion-exchangemedia,

(b) a substantially rectangular inlet chamber adjacent said resinchamber and in liquid communication therewith through a perforatedpartition, and

(c) a spout in one wall of said inlet chamber to admit unsoftencd waterinto said inlet chamber,

(d) said spout having an angled relationship with said wall to directthe incoming water in a substantially diagonal direction across saidinlet chamber.

2. A water softener for use in connection with an automatic washingmachine comprising:

(a) a resin chamber adapted to receive and contain an ion-exchangemedia,

(1)) a substantially rectangular inlet chamber adjacent said resinchamber and in liquid communication therewith through a perforatedpartition, and

(c) a spout in one wall of said inlet chamber to admit a regeneratingsolution into said inlet chamber for regeneration of said ion-exchangemedia,

(d) said spout having a reduced internal diameter to provide increasedvelocity of the regenerating solution as it leaves said spout and enterssaid inlet chamber.

3. The invention of claim 2 wherein said spout has associated therewitha check valve to prevent liquid flow in a direction from said inletchamber.

4. The invention of claim 2 wherein said spout has an angledrelationship with said wall to direct the incoming regenerating solutionin a substantially diagonal direction across said inlet chamber.

5. The invention of claim 2 further comprising a second spout in saidwall to admit unsoftened water into said 'inlet chamber, said secondspout having an angled relationship with said wall to direct theincoming Water in a substantially diagonal direction across said inletchamber.

6. The invention of claim 5 wherein said spout to admit 21 regeneratingsolution has an angled relationship with said wall to direct theincoming regenerating solution in a substantially diagonal directionacross said inlet chamber.

7. A Water softener comprising:

(a) a resin chamber adapted to receive and contain an ion-exchangemedia,

(b) a substantially rectangular inlet chamber adjacent said resinchamber and in liquid communication therewith through a perforatedpartition,

(c) a spout in one wall of said inlet chamber to admit unsoftened Waterinto said inlet chamber, and

(d) means including a conduit to removably interconnect said spout witha source of unsoftened Water,

(c) said means, at least some times, trapping air within said conduitupon connection with the source of unsoftened Water with the trapped airtravelling to said inlet chamber and forming an air lock therein,

(i) said spout having an angled relationship with said wall to directthe incoming water in a substantially diagonal direction across saidinlet chamber to break up and disperse any air lock therein.

References ited UNITED STATES PATENTS 418,335 12/1889 Jewell 2l0l362,265,741 12/1941 Morse 210275 2,292,814 8/1942 Bariffi 68l3 X 2,776,7551/1957 Craig 21G-4S6 X 3,148,687 9/1964 Dosch 68-43 X REUBEN FRIEDMAN,Primary Examiner.

F. SPEAR, Assistant Examiner.

